Ktm 640 safety switches bypass

[WesleyDRZ400]

So my kickstand switch has been bypassed as shown below

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Kickstand switch
Wire cut and both ends twisted together, I will just totally remove the lower wire as its dead and solder together the upper wires and wrap them.

Clutch switch
The switch is worn so rather than get a new one I take it I can basically do the same? Remove switch then join wires together solder and wrap?

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Neutral wires?
Having problems with neutral light going on l, only when it goes on it will start.

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I take it that its the lower single green wire as shown on photo located on the right hand engine case, I tracked it back and half way there was a connector block I disconnected and reconnected and light came on then went out, anyone had this problem, I will trace it right back to under top dash cluster and see what issues is next week however is there a heads up on this fault, and can I bypass it?

[Snaf MKII]

I think the neutral and clutch switch are interlinked as our would start in gear with the clutch lever pulled in. You'll want to make sure the clutch switch adaptions replicate that so that it will start in or out of gear.

[WesleyDRZ400]

I will trace them both back, to see where they interlink. I read on adv rider this

Just cut the two wires going to the clutch sensor and splice them together.
The sensor then always thinks the clutch is pulled in and will allow the starter to engage when you press the starter button. No need to be in neutral to do it.

Both the side stand and clutch switch can cause non starting issues if faulty or worn so best to bypass I think.

I am sure I have a slight exposes cable also shorting on the frame somewhere

[WesleyDRZ400]

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See connector block in photo for the clutch

[WesleyDRZ400]

Finally found the electrical gremlin..... It was the clutch switch wire /neutral light. Just cut it and joined together and turns over first time.

Now can progress with the build, basically just putting it back together making it all fit

[AlanHolt]

Doesn't the side stand switch have to work for the MoT? My 640 failed it's Spanish equivalent 2 years ago because I had bypassed it.

[Snaf MKII]

^^^^^^^^^^^^ Not in the UK, it might however be that the side stand has to flip up when weight is taken off of it so that you can't ride off with it still down. I think this is achievable by removing one of the springs.

Personally if it's not a competition bike I'd prefer to keep the sensors.

[dodursley]

No MOT requirement according to this https://www.gov.uk/guidance/mot-inspect ... otorcycles

[bowber]

I don't think any of the safety switches are on the UK MOT.

I prefer leaving the side stand one working as I've tried to set off a time or two with it down, I'm not bothered about the clutch one but then they are all interlocked in with the side stand, just be thankful it's not like the new KTM ones, the ECU checks the switch is present all the time so you can't just bypass it with a diode or resistor anymore. I now keep a spare switch with a magnet taped to it under the seat as it's easy to break one.

Steve

[catcitrus]

Just curious--you say the ECU checks and it can't be bypassed?. On my WR250R it HAD EXUP but all that is off and replaced with a custom little box with diodes and resistors as the ECU does a check "sweep" when the ignition is turned on and if the motor is open circuit or apparently seized it throws a fault code or two. The sidestand switch is just that, a switch I would have thought--either open or closed circuit, and maybe with some resistance etc--I'm sure someone can come up with a little plug in circuit board and maybe a simple switch to simulate up or down which is out of the muck--IF the ECU expects the stand to be down to start the bike.